Rectifier assembly



Dec. 23, 1.952 L HALL 2,623,104

RECTIFIER ASSEMBLY Filed Aug. 5, 1950 2 SHEETS-SHEET 1 75 2 .5 /l/ di@ Dec. 23, 41952 J. H. HALL 2,623,104

RECTIFIER ASSEMBLY Filed Aug. 5, 1950 2 SI-IEETS--SI'IEET 2 1N V EN TOR.

Patented Dec. 23, 1952 UNITED STATES PATENT i()fl'iF'ICE YRECTIFIER ASSEMBLY James H.fHa'll,Lake Blum Ill., assignorrtoiFan- `steel Metallurgical Corporation, vNorth Chicago,

I1l.,. a. corporation of New York Application August 5, 1950, Serial No; 177,914

1 8f Claims. L1

' This. invention. relatesuto 1.a lrectifier fqassembly, and. more particularlyhto airectier assemblygoi the Vdry disc .type which embodies parts;v terminals and structural relationships adapting it particularly vto ruggedness .and heavy du-ty..service.

The. use, in buses,.tr.ucks andthe like, of, alternato-rerectier .system u for .furnishing electrical power has broughtabout the. need. fora heavy duty rectier ofthe dry disc type which is capable ofswithstanding the-'mechanicalshock and vibrations. encountered insuch service. l Inlsuch. use, the relatively large :electrical capacityrequred notfonly .affects ther size-.and-.mass of :the` rectifier assembly. in. itself, sofas .to increase thesusceptibilityfthereof to damage by-ashockLand vibration, butthe heavy leads required-.subject the. rectiiier andl its terminals to the: mechanical forces l and vibrations of-.such heavy leads .or bus bars. .As another incident i the l large-;electrical...capacity which accompanies the use referredftogthe assembly must be adaptedy to mountingat aplace in whichl there isy an adequatesupply oncoming air, scmewhat'irrespectiveof the'disadvantages which such .placement may have inrespect to shockand vibration.

It is'therefore oneA otthefgeneral-objects =of-my invention to providea rechner-assembly'. having the requisite ruggedness-and v`electrical Icapacity to Iwithstand service l in --an alternator-rechner system of the type used in1buses,'trucks and the like.

fAs-anothe1'-object,- thisv inventionr-comprehends the provision of a rectifier assembly which is adapted, byl structure and arrangement; to l 1use as a part of a cooling1a-ir-ductwith the rectifier elements disposed in the duct,`4 soeasto' Abe-cooled by theowlof air therethrough.

My invention also has Within itsn purview the provision 'of` `a supportingand terminal structure in a rectifier assembly-Which not `only affordsfa solid-V and`V rugged lanchorage for connecting bus bars or` leaclsfbutlwhich i effectively segregates the mechanical forces and vibrationsof suchbus bars orleadsfrom:the'rectier element.

Since excessive pressureI -on'vrectifyingj layersof selenium rectiers-and` the like'is detrimental-to the f operating 'i characteristics of Llsuch rec-tier assemblies,1it -isa` further object off myJ invention toprovide-.a rectifier assembly f embodying structure andl Aan arrangement -of parts suchthat it;

Willwwithstand shocks and-.vibration without the use lof excessive pressure on the rectifyingv layers.

f Other `objects `and advantages of the invention Willwbe apparent `from Ather-followingdescription andtheaccompanying ydrawings in'which similar` ..2 characters .of ,f reference indicate 'lsmilar .aparts throughoutthe. several views.

Referring-.to the two sheets .of drawings,

Figs. land 2 are respectively,side-.elevational and end sectional views illustrating thestructure of va preferredembodimentof my rectifien assemblyand its adaptation to ins tallatiorr` in angar duct;

Fsf is a .top-plan vieworthe structure illustlated in Fie- 2,1d1fawr1. toasomewhatlarseescale than Fig. 2, and viewed; substantially-as indicated by a lineY 3-,3 inV Fig. Zzandaccompanyingarrows;

Fig. 41isa top plan view ofv my: preferred recti- Iier -assernbly-` taken Y substantially Y ons a; ilineilIf-g- 0f Fiel 2. and in; the directionof .the accompanying arrows, and havingsome of'` the parts Vllmizlvecl;

Fig. 5 is a side elevationalviewof the rectifier assembly;

Figs. ;6 and'? are respectivelysend'and topzsectional views` taken" substantially onlines: 6e6,and 'I--l VoFig. 2 `and theydirectons indicated .by accompanying-arrows;

Fig. -l-isv an end elevationalview of oneelement of my disclosed .rectiery assembly; and

Fig. -9is a side; elevational view depictingV :the structure of a preferred type; of terminalutilized in my .disclosed rectinerassembly.

`IntheVI exemplary embodiment of imy, invention which is; depictedgin the accompanying.drawings for illustrativepurloses, I ,have showna. rectier assemblyfwhich is adaptedto .use on a three phase alternating current source, 1 and .-to the provision of` iullwaverectication. In the rectinen art,i it isl known and well understood that yvarious combinations ofV elements of the; type hereinjdisclosed Can bearranged to provide either yfull or .haii-,wave rectification i'or either single or polyphase sources having various voltage ranges. As will. be-.-more readily understood as the. description. progresses, the invention hereindisclosed is not necessarily limited. to.` a particular class or `type of rectifier stack, or` ythe rectication of-anycertain number of phases.

Having referenceto the acccmpanyingdrawings, my. rectifier. assembly includes, in general.r -a rectifier. stack I I- mounted and supported-'between end supporting plates I2 and i3. InY the-dis closed structure, each of the end supporting plates has..top.and bottom flanges Hand l'-respectively. A panel I6 which, in the presentinstance,` is relatively. rigid and made of insulating material, is secured to the topflanges I4 ofthe supporting plates'by fasteningnmeans, such as screws II, and extends between-thesupporting plates' inspaced relationshipto the-top ofthe 3 stack II. Output terminals I8 and I9 and input terminals 20, 22 and 23 are mounted on the panel I6 in spaced relationship to one another.

Referring in greater detail to the structure of the disclosed rectier stack II, it includes a plurality of plates 24, each of which has an adjacent Contact plate or electrode 25, with a layer of material such as selenium between each plate and its adjacent electrode. The plates, each paired with an adjacent electrode, are spaced in the stack by spacing washers 26. The plates, electrodes and spacing washers of a stack have openings 28 in the mid-portions thereof, which openings are of a size to iit snugly upon a tubular insulating member 21, and the openings in at least one of said parts may be of the same configuration as the tubular insulating member. The disclosed rectifier assembly being particularly adapted to withstand shocks and vibrations, and also because excessive pressure has a detrimental effect upon the resistance characteristic of the rectiiier, the external surfaces of the tubular insulating member 21 is made non-circular in form by providing flat side surfaces 29 thereon and corresponding iiat surfaces 33 in the openings 28 of the plates. These at surfaces prevent rotational movements between the parts of the stack without the application of excessive pressure at the ends of the stack for maintaining the parts in their assembled and engaged relationship.

As shown in Fig. '1, spacing washers 32 are provided at the opposite ends of the stack. The tubular insulating member 21 extends through the plates 24, electrodes 25, spacing washers 26 and spacing washers 32 of the stack, as well as through the end supporting plates I2 and I3. A rod 33 having threaded portions 34 at its opposite ends extends through the tubular insulating member 21 and through the mid-portions of the proposed end supporting plates I2 and I3. At opposite ends of the stack, insulating washers 35 separate the spacing washers 32 from the end supporting plates I2 and I3, so as to insulate those end supporting plates from the stack. The spacing washers 32 and the insulating washers 35 serve to space the supporting plates I2 and I3 from the opposite ends of the stack. In the disclosed structure, also, the openings in the end supporting plates I2 and I3 conform to the flat side surfaces of the tubular insulating member to prevent those end supporting plates for turning relative to the stack. The parts of the stack and their associated supporting plates are securely and quite rigidly held in their assembled relationship by fastening means, such as nuts 35 and associated washers 31.

As is understood in the rectiiier art, the number of rectifier elements connected in series in a particular stack is determined by the Voltage rating of the rectifier, and the order and arrangement of the elements in the stack, as well as the positions of the electrical connections to the stack are determined by factors including the number of phases of the input current and whether or not the rectification is to be full or half wave.

In the disclosed full wave rectier for use with a three phase alternating current power source, at connecting strips 38, 39 and 43 have their inner ends anchored at separated positions in the stack between the spacing washers 26 and extend outwradly for connection to the input terminal 20. At another part of the stack, at

connecting strips 42, 43 and 44 have their inner ends anchored between spacing washers at spaced positions in the stack and extend outwardly for connection to the input terminal 22. Likewise, connecting strips 5, 45 and 41 have their inner ends anchored between spacing washers at spaced positions and at another part of the stack, and extend outwardly for connection to the input terminal 23. At other spaced positions in the stack, nat connecting strips 48, 49, 50, 52 and 53 have their inner ends anchored between the spacing washers of the stack and extend outwardly for connection to the output terminal I9. In the same manner, connecting strips 54, 55, 53, 51 and 58 extend outwardly from additional positions in the stack for connection to the output terminal I8.

The structure of the rectier stack being cen.- tered about the rod 33 and tubular insulating member 21, with the stack extending axially therealong, the connecting strips for making connections from the input and output terminals to selected parts of the stack in a particular stack arrangement are grouped with the connecting strips for each terminal in parallel relationship axially of the stack and with the connecting strips for the various terminals spaced circumferentially of the stack.

The terminals I8, IS, 23, 22 and 23 are desirably alike in structure; those utilized in the disclosed assembly being of the type shown in Fig. 9. Each such terminal has a threaded stem portion 59, at one end of which is a flattened end portion 6I), through which end portion there is a cross bore 62. For mounting each of the terminals on the panel I6, as shown in Fig. 6, I have provided a nut 63 which is threaded on to the terminals stem to a position adjacent the flattened end portion 58. Each of the terminals extends through an appropriate bore in the panel I6, with the nut 63 adjacent the inner face of the panel, so that the flattened end portion is between the panel and the rectifier stack. Washers 64 and lockwashers G5 are placed on the terminals on opposite sides of the panel, and a second nut G6 is utilized on each terminal for securing the terminal in place on the panel. A third nut 61 and Washers 68 are provided on each terminal for gripping a connecting lead or bus bar. From this description of the terminals, it may be readily understood that each such terminal is firmly secured to the panel I6, so as to provide a rm anchorage for the connecting leads of bus bars, as well as for the connector strips from the stack.

In order to provide further for the irm lanchorage of each group of connector strips to one of the terminals, as illustrated in Figs. 4 and 6, bolts 69, 10, 12, 13 and 14 extend through the respective cross bores in the flattened end portions 60 of the terminals I8, I9, 20, 22 and 23. Spacing collars 'I5 of appropriate length are placed on the bolts 69, 10, 12, 13 and 14 on opposite sides of their respective terminals and between each of the adjacent connecting strips of a group which is to be attached to a single ter-y minal. The bolts E9, 1li, 12, 13 and 14 extend through the outer ends of the connecting strips of each group, whereby nuts 16 on the respective bolts are tightened to secure the bolts and their respective spacing collars and connecting strips into a relatively rigid assembly which is rmly secured to each of the terminals. Thus, with the disclosed structure, the plates and electrodes of the stack are secured against relative aieearioc rotation, the AAconnecting A.strips `are firmly anchored at their opposite endsto the stack and the.- respective terminals, andthe terminals are anchored. in` a manner which .prevents the transmission of forces and vibrationsthrough the terminals vto the connectingvstrips'and the stack.

-In order to facilitate the assembly of my disclosed rectifier unit, the supporting plates I2 and I3, as shown in Figs. 1 and 5, are provided with openings 11 near the panel I6 and aligned with the bolts Se, 10,12,13 and 14. These openings provide access for tightening the nuts 16 on the respective bolts during assembly. After assembly, plates 18 are secured to each of the supporting plates I2 and I3 by f-astening means, such as screws 19, for covering the openings 11.

In addition to providing a rectifier assembly which is adapted to withstand shock and vibration, the disclosed structure is also adapted to fit into and form a part of an air flow conduit 80, as shown in Figs. 1 and 2. Such placement not only affords a satisfactory mounting position for the rectier but also insures a supply of cooling air which is essential for heavy duty operation. Side plates 82 and 83 which form opposite sides of the conduit 80 are secured to the supporting plates by fastening means, such as screws 84, so that each of the supporting plates fills a gap between spaced end portions of each of the conduit side plates. Likewise, the panel IB covers an opening in a top plate 84 in the conduit, so that the rectifier assembly is removable through the spaces provided between the ends of the rectifier side and top plates. A bottom plate B6 of the conduit 8u is continuous and is secured to the lower fianges I5 of the supporting plates I2 and I3 by fastening means such as screws 81. With the disclosed structure and arrangement, the axis of the stack extends laterally of the conduit and the -cooling air flowing through the conduit passes between the plates and electrodes of the stack to afford effective cooling action with a minimum of resistance to the air flow through the conduit.

While I have illustrated a preferred embodiment of my invention, many modifi-cations may be made without departing from the spirit of the invention, and I do not wish to be limited to the precise details of construction set forth, but desire to avail myself of all changes within the scope of the appended claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent of the United States is:

1. A rectifier assembly comprising, in combination, a rectifier stack including a plurality of plates and electrodes arranged in pairs separated by rectifying layers and wherein the pairs are separated by spacing washers and disposed and electrically connected to provide a predetermined rectifyng circuit, a tubular insulating member, said plates, electrodes and washers having openings therein and being assembled together on the tubular insulating member, the external surface of said tubular insulating member and said openings in the plates being similarly shaped with flat surface portions to prevent rotational movements of the plates, flanged supporting plates insulated from the stack and mounted at opposite ends of the stack, said flanged plates being disposed over said tubula-r insulating member and having openings corresponding to the section of said insulating member so that said flanged plates are rotatively locked to said insulating member, fastening means -extending through the tubular insulating. member'for securing theistack 4and supporting Y plates in assembled i. relationship, an inlsulating panel secured., to the supporting, plates, terminals secured to the insulatingpanel, V,and electrically conductive connecting strips each having their opposite ends anchored to one of the terminals and between Said spacing washers.

2. A rectifier assembly as defined in claim 1 adapted to use for providing direct current output to a single pair of terminals from a polyphase alternating-current source, -and wherein said terminals include two outputiterminals and a plurality of input terminals,` and eachofsaid output terminals having a plurality of said connecting strips anchored thereto through a laterally extending and substantially rigid post structure having a rigid spacing element extending between the connecting strips connected thereto.

3. A rectifier assembly as defined in claim 2, and wherein each of said input terminals has a plurality of said connecting strips anchored thereto through a laterally extending and substantially rigid post structure having a rigid spacing element between the connecting strips connected thereto.

e. A rectier assembly comprising, in combination, a rectifier stack of the dry-disc type, support plates secured to opposite ends of the stack and electrically insulated therefrom, a panel secured to and extending between the support plates in spaced relationship to the stack, terminals secured to the panel in spaced relationship to one another, cross posts of rigid construction rigidly secured to each of the terminals between the panel and the stack, a plurality of electrically conductive connecting strips extending outwardly at spaced positions along the stack for making electrical connections thereto, and a plurality of said connecting strips rigidly secured at fixed and spaced positions to each of said cross posts.

5. A rectifier assembly as defined in claim 4, and wherein said terminals comprise screws with laterally flattened end portions, said flattened end portions having bores therethrough transverse to the screw axes, and said cross posts including threaded members carrying tubular spacers on opposite sides of the flattened end portions.

6. In a rectifier assembly, the combination comprising a rectifier stack including a plurality of plates and electrodes, said plates and electrodes each having an opening through the midportion thereof, a tubular member of insulating material fitting snugly in the openings of the plates and electrodes, the openings in said plates and electrodes being non-circular and conforming to the exterior sectional shape of the tubular member to prevent rotational movement of the plates and electrodes relative thereto, a rod extending axially through the tubular member and having a threaded end portion projecting from the tubular member, support plates secured to the stack at opposite ends of the rod, a panel secured to the support members, and terminals mounted on the panel and electrically connected to the stack.

7. In a rectifier assembly as defined in claim 6, .said support plates having openings therein for receiving the tubular member and conforming thereto to prevent relative rotational movements between the support plates and the stack.

8. In a rectifier assembly, the combination comprising a rectier stack, a relatively rigid panel fixedly secured to the stack and extending along one side of the stack in spaced relation- REFERENCES CITED The following references are of record in the le of this patent:

Number 8 UNITED STATES PATENTS Name Date Geiger Sept. 17, 1929 Auman Apr. 21, 1931 Ruben June 28, 1932 Zierdt July 5, 1932 Hughes et al Feb. 24, 1942 Richards Jan. 27, 1948 

